Interactive liquid spraying system and method

ABSTRACT

An intelligent spray nozzle, comprising an input pressure sensor, a flow rate sensor, a flow modulator, a nozzle pressure sensor, a linear actuator, and an output orifice modulator, wherein an input pressure read from the input pressure sensor and a flow rate read from the flow rate sensor are used as inputs by the flow modulator to drive the at least one linear actuator to control an output spray rate from the intelligent spray nozzle, and wherein a nozzle pressure read from the nozzle pressure sensor is used as feedback for the output orifice modulator, wherein an output orifice is modified by the output orifice modulator to achieve optimal output spray.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.15/228,991, now U.S. Pat. No. 10,518,284, which claims priority in U.S.Provisional Patent Application No. 62/201,010 filed Aug. 4, 2015, whichis incorporated herein by reference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

This invention relates generally to the spray application of chemicals,and more specifically to a liquid spraying system configured forautomatically adjusting spray patterns utilizing interactive spraynozzle adjustments.

2. Description of the Related Art

Spraying systems have utilized a wide variety of adjustable nozzleconfigurations and spray operation controls, which are generally basedon the liquids being sprayed, environmental factors and otheroperational considerations. Without limitation, an exemplary applicationof the present invention is in a mobile agricultural spraying system,which applies liquids to field crops. For example, such liquids cancomprise herbicides, pesticides, liquid fertilizers, nutrients and othersubstances facilitating crop yields.

The spraying system operating condition variables include pump pressure,discharge nozzle configurations and fluid flow rates. These and otheraspects of spraying systems can be controlled to deliver more or less ofthe liquid to the target surfaces. However, changing the operatingpressures and the flow rates in spraying systems can have adverseeffects on other operational variables, such as droplet sizes. If thedroplet size created is too small, the spray becomes susceptible todrift in even a light breeze, such that chemicals may drift over theintended target and settle on an unintended target, such as non-cropland, a water supply, animals, or people. Such drift issues can thushave negative effects on spraying operations.

Other environmental conditions can also affect agricultural sprayingsystem performance. For example, temperature and humidity can affectspray material droplets and change plant absorption of the sprayedchemicals.

An effective spraying system, especially for agricultural applications,preferably provides selective and/or individual control of each spraynozzle. This can help avoid overlapping chemical applications, enablesectional control (allowing varying amounts of chemical to be applied atdifferent locations, e.g., based on criteria such as sensor readings andpre-determined field conditions), and compensate for blocked nozzles andother system issues.

The present invention addresses such spraying system issues. Heretoforethere has not been available an interactive liquid spraying system andmethod with the advantages and features of the present invention.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, an interactivespraying system includes an intelligent spray nozzle with an inputpressure sensor, a flow rate sensor, a flow modulator, a nozzle pressuresensor, a linear actuator, and an output orifice modulator, wherein aninput pressure read from the input pressure sensor and a flow rate readfrom the flow rate sensor are used as inputs by the flow modulator todrive the at least one linear actuator to control an output spray ratefrom the intelligent spray nozzle, and wherein a nozzle pressure readfrom the nozzle pressure sensor is used as feedback for the outputorifice modulator, and wherein an output orifice is modified by theoutput orifice modulator to achieve optimal output spray.

These and other aspects are achieved by the present invention, which isdescribed in detail in the following specification and the accompanyingdrawings which form a part hereof.

BRIEF DESCRIPTION OF DRAWINGS

The drawings constitute a part of this specification and includeexemplary embodiments of the present invention illustrating variousobjects and features thereof.

FIG. 1 is a block diagram showing one embodiment of an interactiveliquid spraying system embodying an aspect of the present invention.

FIG. 2 is a block diagram illustrating a potential design for thespraying system for enabling flow control and spray pattern shaping foran intelligent spray nozzle.

FIG. 3 is an illustration of how a flow sensor and pressure sensor maybe integrated into the spraying system to provide control feedback andmonitoring.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT I. Introduction andEnvironment

As required, detailed aspects of the present invention are disclosedherein, however, it is to be understood that the disclosed aspects aremerely exemplary of the invention, which may be embodied in variousforms. Therefore, specific structural and functional details disclosedherein are not to be interpreted as limiting, but merely as a basis forthe claims and as a representative basis for teaching one skilled in theart how to variously employ the present invention in virtually anyappropriately detailed structure.

Certain terminology will be used in the following description forconvenience in reference only and will not be limiting. For example, up,down, front, back, right and left refer to the invention as orientatedin the view being referred to. The words, “inwardly” and “outwardly”refer to directions toward and away from, respectively, the geometriccenter of the aspect being described and designated parts thereof.Forwardly and rearwardly are generally in reference to the direction oftravel, if appropriate. Said terminology will include the wordsspecifically mentioned, derivatives thereof and words of similarmeaning.

II. Preferred Embodiment Interactive Liquid Spraying System 2

With reference to the drawings, an interactive liquid spraying system 2is described.

In general, the overall aspects of the invention, which is aninteractive liquid spraying system 2, are as follows:

-   -   Spray nozzles 4 (FIG. 2) function as “intelligent” nozzles in        the spraying system 2, and automatically adjust the droplet        sizes as the flow rate is changed in order to ensure controlled        and consistent droplet sizes across all flow rates.    -   The intelligent spray nozzles 4 allow individual control,        wherein each such intelligent spray nozzle 4 in the system 2 can        be controlled independently of all other nozzles 4.    -   The intelligent spray nozzles 4 include adjustable orifice        openings to aid in droplet size control and spray pattern        shaping.    -   The spraying system 2 includes a microprocessor 6 programmed for        operating the system 2 in response to various inputs.    -   The spraying system 2 is configured for automatically adjusting        the nozzle/flow pressure for a given input pressure via a        pressure controller 8.    -   The intelligent spray nozzles 4 are electrically actuated and        controlled, allowing both flow rate control and nozzle opening        control.    -   The system 2 includes a fluid input 10, which can include a        pump, an input pressure sensor 12, a precision flow sensor 14        for control feedback and monitoring and a flow modulator 16.    -   Each intelligent spray nozzle 4 includes a precision nozzle        pressure sensor 18 for control feedback and monitoring.    -   Each intelligent spray nozzle 4 includes a linear actuator 20        connected to an output orifice modulator 22 for controlling a        spray pattern 42 from a spray output or nozzle outlet 24.    -   The system 2 includes blockage monitoring using the flow sensors        14 associated with the nozzles 4.

FIG. 1 is a block diagram showing one embodiment of the invention in aspraying system 2. In this embodiment, fluid 26 is received in the fluidinput and pump 10 from a fluid source 28, e.g., a tank mounted on amobile piece of equipment and containing a quantity of liquid 26 forspraying with the system 2. The fluid input can be a simple opening intoa conduit or cavity, such as the interior of the nozzle housing, throughwhich the fluid 26 can flow. The fluid 26 flows past the input pressuresensor 12 so that the input pressure can be obtained, and past a flowsensor 14 so that the rate of flow of the fluid can be obtained.

This information (the input pressure and flow rate) is passed into theflow modulator module 16, which uses the sensor information as well asthe user-defined or pre-defined “desired” application rate and,optionally, environmental information (wind, weather, etc.) to determinethe proper way to drive the linear actuator 20 which will control thesize and shape of the output orifice opening 30 (through the outputorifice modulator 22). The liquid 26 will also flow past a nozzlepressure sensor 18 and the information obtained (the pressure of thefluid inside the nozzle body 32) will also be used by the output orificemodulator 22 to determine the best shape for the output orifice opening.

The size and shape of the output orifice opening 30 will be modulated tohelp determine the pressure of the spray output and its shape andpattern, and it will also have an effect on droplet size.

FIG. 2 shows the internal construction of the spray nozzle 4 withcomponents enabling flow control and spray pattern shaping for anintelligent spray nozzle 4. This design represents one possibleembodiment and is not meant to be limiting. FIG. 2 shows a cutaway orsectional view of the intelligent spray nozzle 4, showing the internalconstruction.

Fluid 26 enters the nozzle through the fluid input or inlet 10, whichincludes a suitable pump for pumping the fluid 26 from the fluid source28 through the system 2. The fluid 26 then flows through a flow controlopening 36 toward the orifice opening 30. The amount of fluid 26 passingthrough the flow control opening 36 (the flow rate of the fluid) can becontrolled by a flow control feature 34, which can be raised and loweredby the actuator 20 such that it moves either out of or farther into theflow control opening 36 via a connecting rod and return springsubassembly 21, reducing the amount of fluid 26 that can flow throughthe flow control opening 36 at a given time. The actuator 20 is drivenby commands from the flow modulator 16 (see FIG. 1).

Once the fluid 26 flows through the flow control opening 36, it flowsinto the orifice opening 30 where it will exit the nozzle 4 through thenozzle outlet 24. An orifice shape feature 38 is controlled by theactuator 20 via a plunger shaft 40 connection such that the orificeshape feature 38 moves into and out of the orifice opening 30, wherebythe orifice shape feature 38 opens or closes the orifice opening 30 bychanging its size and shape of the orifice, thus functioning as a flowcontrol valve controlling the spray pattern and flow rate.

Ideally, both the flow control feature 34 and the orifice shape feature38 can be moved using a single actuator 20, connected via a commonplunger shaft 40. In alternate embodiments, however, the orifice shapefeature 38 can move independently of the flow control feature 34, andtwo or more actuators 20 can be used in these embodiments.

The control of fluid 26 flow through the flow control opening 36 and theshape and size of the orifice opening 30 will ultimately create theshape and behavior of the spray pattern 42 emerging from the sprayoutput or nozzle outlet 24.

FIG. 3 is a cross-sectional view of a flow and pressure sensor subsystem41 housed in a section of a flow conduit or pathway section 44. Thesensor subsystem 41 is adapted for use in the interactive liquidspraying system 2 of the present invention and provides feedback andmonitoring of performance parameters of the system 2. The flow conduitor pathway 44 can be fully integrated into the body or housing 32 of anintelligent spray nozzle 4. The flow of fluid 26 is shown in FIG. 3 byarrows.

A pressure transducer 46 is introduced in the wall of the flow conduit44 or embedded inside the conduit, and it senses the pressure of thefluid 26 in the conduit 44. An enlarged section 48 of the flow conduit44 bulges out such that conduit walls 50 that are more or lessperpendicular to the flow of fluid are created, and a chamber 52 formeasuring fluid flow is created. At one end of the enlarged section 48of conduit, an ultrasonic transducer 54 is placed, and an ultrasonicreceiver 56 is placed at an opposite end of the enlarged section 48. Thepressure transducer 46 emits waves of ultrasonic energy which aredetected by an ultrasonic receiver 56.

Measuring the flow rate of a fluid using ultrasonic energy is wellknown. The “time of flight” of the ultrasonic energy to move fromtransducer to receiver is measured in still water and then again inflowing water, and the change in time of flight between the two helpsdetermine the flow rate.

In addition to using the ultrasonic energy to measure the flow rate, itmay be used to determine whether the proper amount of chemical is addedto a mixture. For example, the time of flight for ultrasonic energy tomove a known distance in pure, still water is known. If a known chemical(with its own known time of flight values) is introduced into the water,and then the time of flight in the still mixture is measured, and thedifference measured between the new rate and that of pure water can beused to measure the amount of chemical that was introduced into the purewater. Once this mixture is determined, additional chemicals can beintroduced one at a time in the same manner, using the changing time offlight to determine the amounts of any new chemicals introduced.

Additional features and alternate embodiments are possible withoutdeviating from the intent of the inventive concept described here. Someof these ideas are captured in the Appendix to this specification, whichcontains selected slides with notes on design options.

The examples shown in the figures and described above are intended to beexemplary only and are not meant to be limiting in anyway.

Having this described the invention, what is claimed as new and desiredto be secured by Letters Patent is:
 1. An interactive liquid sprayingsystem, which comprises: a fluid source adapted for containing aquantity of spraying liquid; a pump with an inlet connected to the fluidsource; a flow conduit connected to the pump; a nozzle body connected tothe flow conduit and including a nozzle outlet, the nozzle bodycomprising: a flow control opening in the nozzle body; a flow controlfeature adjustably received in the flow control opening and configuredfor adjusting a passage of liquid through the flow control opening; anorifice opening in said nozzle body located downstream from said flowcontrol opening; an orifice shape feature adjustably received in theorifice opening, said orifice shape feature configured for adjusting apassage of liquid through said orifice opening; and at least oneactuator connected to said flow control feature and said orifice shapefeature, the at least one actuator configured to move said flow controlfeature and said orifice shape feature to adjust a spray pattern fromthe nozzle outlet, wherein the spray pattern is adjusted by extendingsaid flow control feature in said flow control opening while extendingsaid orifice shape feature in said orifice opening, or the spray patternis adjusted by retracting said flow control feature from said flowcontrol opening while retracting said orifice shape feature from saidorifice opening.
 2. The spraying system according to claim 1, whichincludes: an input pressure sensor connected to said flow conduit; aflow sensor connected to said flow conduit; a microprocessor connectedto said input pressure sensor, said flow sensor and said at least oneactuator; and said microprocessor being programmed for actuating said atleast one actuator in response to a predetermined fluid pressure andflow conditions sensed by said input pressure sensor and said flowsensor respectively.
 3. The spraying system according to claim 1, whichincludes a flow modulator connected to said flow conduit and configuredfor modulating a fluid flow through said nozzle body.
 4. The sprayingsystem according to claim 4, which includes an output orifice modulatorin said nozzle body, said output orifice modulator configured foradjusting said orifice opening with said at least one actuator.
 5. Thespraying system according to claim 4, which includes: a fluid inletconnected to said flow conduit and said nozzle body; and said fluidinlet mounting said at least one actuator and said flow control feature.6. The spraying system according to claim 1, which includes: said flowconduit including an enlarged section located between said pump and saidnozzle body; an ultrasonic transducer mounted on said conduit enlargedsection; an ultrasonic receiver mounted on said conduit enlarged sectionand oriented to receive ultrasonic transmissions from said ultrasonictransducer, said ultrasonic receiver configured for generating signalsrepresenting fluid flow in said conduit enlarged section; and amicroprocessor connected to said ultrasonic receiver and programmed forcontrolling said spraying system in response to said fluid flowrepresentative signals.
 7. A method of controlling a liquid sprayingsystem including a fluid source, a pump connected to said fluid source,a flow conduit connected to said pump, and a nozzle body connected tosaid flow conduit having a nozzle outlet, which method includes thesteps of: providing a flow control opening between said flow conduit andsaid nozzle body; adjustably controlling said flow control opening witha flow control feature selectively received therein; providing anorifice opening in said nozzle body; adjustably controlling said orificeopening with an orifice shape feature selectively received therein;providing at least one actuator mounted on said flow conduit andconnected to said flow control feature and said orifice shape feature;and actuating said at least one actuator to adjust a position of saidflow control feature and said orifice shape feature to adjust a spraypattern from the nozzle outlet, wherein the spray pattern is adjusted byextending said flow control feature in said flow control opening whileextending said orifice shape feature in said orifice opening, or thespray pattern is adjusted by retracting said flow control feature fromsaid flow control opening while retracting said orifice shape featurefrom said orifice opening.
 8. The method according to claim 8, whichincludes the additional step of providing a microprocessor programmedfor automatically controlling said actuator in response to operatingconditions of said spraying system.
 9. The method according to claim 9,which includes the additional steps of: providing a pressure transducerconnected to said flow conduit; sensing with said pressure transducerfluid pressures in said flow conduit; and providing fluid pressuresignal output from said pressure transducer to said microprocessor. 10.The method according to claim 9, which includes the additional steps of:providing an ultrasonic transducer and an ultrasonic receiver in saidflow conduit; generating ultrasonic signals with said transducer;receiving said ultrasonic signals with said receiver; providing outputsignals from said receiver representing fluid flow characteristicsthrough said flow conduit; and communicating said output signals fromsaid receiver to said microprocessor.